Door Handle Adapter with Compressible Spacer and Springs
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Solution Overview
Problem
Sprung door levers often sag and experience loose connections due to play in the latch mechanism, leading to suboptimal operation and alignment issues.
Innovation Solution
A door handle adapter with a spindle, hub, engagers, slider, springs, and a compressible spacer that maintains a positive engagement between the spindle and hub, preventing sagging and loose connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tighter tolerances are used to reduce play in the latch mechanism, then connection stability is improved, but manufacturing complexity and alignment difficulty increase
Solution Approach 1:
The patent introduces a hub as an intermediary component between the spindle and the latch mechanism. The hub provides a standardized interface with engagement features (such as keys or splines) that positively transmit rotational force while absorbing manufacturing tolerances. This mediator allows standard tolerances to be used without compromising connection stability, resolving the contradiction between reliability and manufacturing complexity.
2Stability of the object's composition
If a stronger spring is used to prevent lever sagging, then lever position stability is improved, but operational force requirement increases
Solution Approach 1:
The patent addresses lever sagging not by increasing spring force in the traditional sense, but by providing positive mechanical support through the hub and engagement features. The hub's structural support in a different dimension (mechanical positioning) reduces the burden on the spring, allowing a lighter spring to maintain lever position stability without increasing operational force requirements.
3Ease of manufacture
If standard tolerances are used in latch mechanism components, then ease of manufacture is improved, but connection play and free-play increase
Solution Approach 1:
The patent segments the connection system into distinct components (spindle, hub, engagement features) with standardized interfaces. Each component can be manufactured independently with standard tolerances, yet the segmented design with positive engagement features ensures that connection stability is maintained. The segmentation allows tolerance accumulation to be managed at each interface rather than requiring tight tolerances throughout the entire assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adapter ensures the door lever maintains a horizontal position without sagging and provides a secure connection to the latch mechanism, minimizing free-play and improving operational efficiency.
Implementation Method 1
a compressible spacer that maintains a positive engagement between the spindle and hub
Data Source
AI summary
An adapter for either a handle set or a lever set door lever is equipped with a pair of springs to provide a pre-load on the spindle. The pre-load prevents sagging of the lever due to the large mass of the lever. A sleeve in the adapter is formed out of a compressible material that accepts the spindle in a press-fit configuration. This allows for greater manufacturing tolerances while still providing a solid and secure engagement between the spindle and the adapter. As a result, any free play in the lever is eliminated and the lever is maintained in a horizontal, home position when the lever is not in use. Following use through rotation of the lever, the springs promptly return the lever back to the home position while the sleeve prevents any slop or free-play in the lever's motion.